Method of producing an ornamental design in stone



R. B. PERRY Feb. 16, 1937.

METHOD OF PRODUCING AN ORNAMENTAL DESIGN IN STONE Filed July 15, 1934 2Sheets-Sheet 1 EberzEYQ-rxy f a? w aim.

R. B. PERRY 2,071,086

METHOD OF PRODUCING AN ORNAMENTAL DESIGN IN STONE Feb. 16, 1937.

Filed July 15, 1934 2 Sheets-Sheet 2 Per/ Patented Feb. 16, 1937 UNITEDSTATES PATENT OFFICE METHOD OF PRODUCING AN ORNAMENTAL DESIGN IN STONEof Vermont Application July 13, 1934, Serial No. 735,007

6 Claims.

This invention relates to the production of ornamental designs in stoneand particularly to the production of designs in granite memorials bysand blast operations.

It is the general object of my invention to provide an improved methodof producing such ornamental designs by successive sand blastoperations, particularly when the design includes contoured elements.

A further object is to provide an improved method of using successivestencils in the production of a contoured ornamental design in stone bysand blast operations.

My invention further relates to an ordered procedure which will behereinafter described and more particularly pointed out in the appendedclaims.

Successive features of the invention are shown in the drawings, in whichFig. 1 is a partial plan view of a stencil used in practicing myimproved method;

Fig. 2 is a similar view of a second stencil;

Fig. 3 is a sectional elevation of a stencil, taken along the line 33 inFig. 1;

Fig. 4 is a detail sectional view showing the first stencil applied to ablock of stone, taken along the line 4-4 in Fig. 1;

Figs. 5, 6 and 7 are views similar to Fig. 4 but showing successivesteps in my improved method;

Fig. 8 is a sectional elevation of the ornamented stone after the secondstencil has been removed;

Figs. 9, 10 and 11 are sectional elevations similar to Figs. 4 to 7 andrelating to the production of a screen background;

Fig. 12 is a plan view of a finished carving;

Fig. 13 is a partial plan view of an additional stencil, and

Fig. 14 is a partial front elevation of a monument and illustrates theuse of the stencil shown in Fig. 13.

Referring to the drawings, my improved process of producing anornamental design by the use of a sand blast involves the use ofsuccessive stencils, such as are designated B and C in Figs. 1 and 2.Each stencil is preferably formed. of separate layers, as indicated inFigs. 1 and 3, the preferred form consisting of a middle sheet 20 ofzinc or other suitable metal, and the upper and lower layers 2| and 22being of sheet rubber or some similar composition.

The middle layer 20 gives stiffness to the stencil C or B and holds allparts of the design in the desired relation, while the upper rubber orcomposition layer 2| resists the action of the sand blast in thewell-known manner, and the lower rubber or composition layer 22 fitssnugly against the surface of the stone and may be secured thereto by asuitable cement or other 3 adhesive if desired.

The stencil B is provided with openings 25 which correspond to theoutlines of the leaves, flowers or other elements of the design whichare to be contoured in the finished product.

The stencil C is provided with background openings 27 and with outlinegrooves 28, which openings and grooves surround the stencil portions 30which correspond to the design to be produced. These parts may beconnected by narrow tie pieces 31 wherever necessary.

In the production of a sand blast design by my improved method, I firstprepare the stencils as above described and then place the stencil B onthe surface of the stone or granite block in which the design is to beproduced. The stencil may be held in position by any desired means butpreferably by the use of a non-staining cement or adhesive. This step inthe process is illustrated in Fig. 4.

I then apply a controlled or pencil sand blast S through each opening 25in the stencil B and produce the desired contoured design element asnarrow slots as indicated at 33 (Figs. 2 and '7).

I then apply a general sand blast against the surface of the stencil C,which sand blast will operate through the openings 21, 28 and 33 toproduce the background portions 31, the outline grooves 38 and the veins39, all as shown in Fig.

'7. It should be noted that no separate operation is necessary to sinkthe veins.

The stencil C is then removed, leaving the completed design as shown insection in Fig. 8.

From the above description it will be seen that my improved method maybe quickly and easily carried out, that it involves no long waitingperiods for the drying of glue or composition applied to a stone, andthat the stencils may be previously prepared and held in readiness foruse.

In the previous procedure, as shown for instance in the patent to Chase,No. 1,803,891, it was necessary to apply two or more separate coatingsof glue or composition and to let each coating slowly dry before workcould proceed. It was also necessary to outline and cut the design ineach coating of glue after the application thereof to the stone. In myimproved process, however, the same stencils may be used repeatedly, andtwenty or more copies of a design may be produced by use of the samestencils.

If it is desired to produce a background having a non-continuoussurface, such as the screen 7 background described in the Sanborn andHaslam Patent No. 1,500,272, issued July 8, 1924, I place a Wire orother screen over the stencil C as shown in Fig. 9 after the sand blastoperation indicated in Fig. '7, and I then apply the sand blast a secondtime as indicated in Fig. 10, thus producing grooves or depressions 42in the background and attaining the result indicated generally at 44 inFig. 12. It will be understood that the design of the background may bevaried by changing the type of screen 40.

It frequently happens that a design is to be applied to a monumentalstone on which a polished surface as (Fig. 14) has been alreadyproduced. It is found that sand blast designs are much more pleasing andeffective when produced in a plain surface rather than in a polishedsurface. Accordingly, I sometimes provide an additional stencil A (Fig.13) having an opening 52 corresponding to the peripheral outline of thedesign to be produced.

When sand blasting a design in a polished surface, I first apply thestencil A and direct a light sand blast through the opening for a periodof time just suflicient to remove the polish from the surface. I thenproceed as previously described, using the stencils B and C, and thewire screen 40 if so desired.

By the method above described I am able to produce contoured designs ingranite or other stone at a very substantial saving of both time andlabor. The advantages of my improved process are particularly noticeablein the case of rush orders, as a contoured design may be entirelycompleted in a few hours by using my new method, whereas under thepreviously known methods a period of several days was required, whichperiod was frequently extended by adverse weather conditions.

Having thus described my invention and the advantages thereof, I do notwish to be limited to the details herein disclosed, otherwise than asset forth in the claims, but what I claim is:-

1. The method of producing an ornamental design in stone which comprisesapplying a first separate and previously prepared stencil havingopenings corresponding to the parts of the design to be contoured to thesurface to be ornamented, directing a controlled blast of abrasivematerial through said openings to produce contoured surfaces below saidopenings, removing said first stencil, applying a second separate andpreviously prepared stencil with openings therein surrounding thecontoured surfaces with its edges registering with the edges of saidsurfaces previously produced, and blasting the stone through theopenings in said second stencil to produce a background for saidcontoured portions, the blast being so directed that either thebackground or the contoured surface has sloping walls.

2 The method of producing an ornamental design in stone which comprisesapplying a first separate and previously prepared stencil havingopenings corresponding to the parts of the design to be contoured to thesurface to be ornamented, directing a controlled blast of abrasivematerial through said openings to produce contoured surfaces below saidopenings, removing said first stencil, applying a second separate andpreviously prepared stencil having differently placed openings andhaving unremoved po-rtions corresponding to the openings in said firststencil, said second stencil when applied having said unremoved portionscovering and protecthing said contoured surfaces and having the openingsin said second stencil out of alignment with said contoured surfaces,and blasting the stone through the openings in said second stenoil toproduce a background for said contoured portions, the blast being sodirected that either the background or the contoured surface has slopingwalls.

3. The method of producing an ornamental design in stone as set forth inclaim 2, in which narrow slots are provided in the unremoved portions ofthe second stencil and in which the sec- 0nd blast of abrasive materialis directed through said slots to form grooves in the contoured surfacespreviously produced, said grooves being formed simultaneously with theproduction of the background.

4. The method of producing an ornamental design in stone which comprisesapplying a first separate and previously prepared stencil havingopenings corresponding to the parts of the' design to be contoured tothe surface to be ornamented, directing a controlled blast of abra sivematerial through said openings to produce contoured surfaces below saidopenings, removing said first stencil, applying a second separate V andpreviously prepared stencil .having differently placed openings andhaving unremoved portions corresponding to the openings in said firststencil, said second stencil when applied having said unremoved portionscovering and.

protecting said contoured surfaces and having the openings in saidsecond stencil out of alignment with said contoured surfaces, blastingthe Stone through the openings in said second stencil to produce abackground for said contoured portions, and in thereafter placing ascreen over said second stencil and further applying the blast toprovide said background with a non-continuous surface, the blast beingso directed that either the background or the contouredsurface hassloping walls.

5. The method of producing an ornamental design on a stone having apolished surface which comprises placing a first separate and previouslyprepared stencil having an opening corresponding to the peripheraloutline of the proposed design on said polished surface, lightly cuttingsaid polished surface through said opening with abrasive material toremove the polish from the corresponding area of the stone, applying asecond separate and previously prepared stencil having openingscorresponding to the parts of the design to be contoured to said area,directing a controlled blast of abrasive ma-- terial through theopenings in said second stencil to produce contoured surfaces below saidopenings, removing said second stencil, applying a third separate andpreviously prepared stencil having differently spaced openings andhaving unremoved portions corresponding to the openings in said second.stencil, said second stencil when applied having said unremoved portionscovering and protecting said contoured surfaces and having the openingsin said third stencil out of alignment with said contoured surfaces, andblasting the stone through the openings in said third stencil to producea background for said contoured portions.

ROBERT B. PERRY.

